Modular Gauging Element Assembly

ABSTRACT

A modular gauging element assembly for a tufting machine is provided that allows for broken and damaged gauging elements of the tufting machine to be replaced. The modular gauging element assembly includes a series of gauge modules each having a module body including a series of spaced slots in which gauge elements are received. Locating devices help position the gauge modules along their gauge bars, after which the gauge modules can be mounted in place by fasteners received through the gauge modules.

CROSS REFERENCE TO RELATED APPLICATIONS

The present patent application is a formalization of previously filed, co-pending U.S. provisional patent application Ser. No. 60/913,948, filed Apr. 25, 2007. This patent application claims the benefit of the filing date of the cited provisional patent application according to the statutes and rules governing provisional patent applications, particularly USC § 119(e)(1) and 37 CFR § 1.78(a)(4) and (a)(5). The specification and drawings of the provisional patent application are specifically incorporated herein by reference.

FIELD OF THE INVENTION

The present invention generally relates to the design and assembly of gauge parts for tufting machines, and in particular to gauge modules for tufting machines to enable easy and efficient replacement of the gauging elements in a tufting machine.

BACKGROUND OF THE INVENTION

During the operation of tufting machines, a series of needles mounted along a reciprocating needle bar and carrying a series of yarns penetrate a backing material and are engaged by a series of hooks or loopers for forming cut and loop pile tufts of yarn in the backing material. Such engagement requires close precision in the positioning and operation of the needles and the hooks or loopers to ensure efficient and accurate operation of the tufting machine. During assembly of the tufting machines, therefore, it is important that the needles, loopers, hooks, and/or other gauge parts be accurately mounted along their respective gauge bars to ensure that such gauge parts are accurately and consistently spaced and positioned along their gauge bars. If the gauge parts are misaligned, the individual gauge parts can become broken or damaged, and tufts of yarns can be mis-sewn, resulting in inaccurate or irregular patterns being formed, which carpets have to be discarded.

Accordingly, it has been common practice to assemble gauge parts, such as loopers or hooks in modules, including cast modules in which the loopers or hooks are cast or mounted in a solid block or module, typically including five to ten, or more, individual gauge parts, precisely spaced in a series. These modules then are mounted on a gauge bar to help ensure substantially consistent and accurate spacing of the gauge parts. One problem that arises, however, is that typically with such cast modules, especially where such modules are used in smaller gauge (i.e., 10 gauge or less) tufting machines, if a single gauging element or part fails, (such as becoming broken or dull), the whole gauge module generally must be replaced. Such replacement of the modules is often time consuming and expensive and can require removal and replacement of several undamaged or fully functional gauging elements or parts within each of the modules, which leads to potential waste of other gauging elements or parts in the module that are still operable.

Accordingly, it can be seen that a need exists for an easily replaceable gauge module that addresses the foregoing and other related and unrelated problems in the art.

SUMMARY OF THE INVENTION

Briefly described, in one embodiment, the present invention generally relates to a modular gauging element assembly for use in a tufting machine that facilitates and enables easy and accurate installation and replacement of gauge elements or parts of the tufting machine, including needles, loopers, or hooks. The modular gauging element assembly generally includes an elongated gauge bar, such as a hook bar, needle bar, etc., typically having a series of spaced openings or recesses in which a series of gauge modules are received. A shoulder or ledge further is formed along a lower or bottom edge of each gauge bar, extending beneath the recesses or openings for receiving the gauge modules.

Each of the gauge modules generally includes a module body having front and rear faces, parallel sides, and upper and lower portions terminating at upper and lower edges, respectively. A series of spaced openings or slots generally can be formed in the module body of each gauge module, spaced in series across the top and front faces of each module body. A series of gauging elements or gauge parts generally will be received within such slots or openings formed in the module bodies. Such gauging elements generally can include loop pile loopers, cut pile hooks, level cut loop loopers or hooks, needles, reeds, or other gauge parts. Such gauging elements can be removably secured within the body of the gauge module, such as by one or more fasteners inserted within and engaging or holding the gauging elements in place, or can be cast in place in the modules, with the gauge modules being cast from a metal material such as aluminum or other similar material.

The gauge modules further will include one or more guide members or locating elements/devices such as a tab, one or more pins or projections, a detent, or other similar locating device mounted or formed along the rear side surface of each gauge module. Such locating devices are adapted to engage or fit within the corresponding openings or slots formed along the gauge bar for receiving the gauge modules, to assist in mounting the gauge modules to the gauge bar in a desired horizontal alignment or position.

In addition, a locating element or member generally can be formed along the lower portion of each gauge module along the rear sides surface thereof, and can include a ledge or other similar projection, pin, or other elements adapted to engage the shoulder or ledge formed along the lower edge of the gauge bar to help provide a vertical fixation point for the gauge modules. As a result, the gauge modules each can be located in a desired position both horizontally and vertically along the gauge bar, and can be provided with further support for resisting any upward pulling movement of the yarns acting thereon during a tufting operation. Thereafter, a fastener, such as a set screw or other similar fastener can be received through each gauge module and through a corresponding opening formed in the gauge bar for securing the gauge modules to the gauge bar.

Various features, objects and advantages of the present invention will become apparent to those skilled in the art upon a review of the following detailed description, when taken in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF DRAWING

FIG. 1 is a side elevational view of a tufting machine including the module gauging element assembly according to one embodiment of the invention.

FIG. 2 is an exploded prospective view of a modular gauging element assembly according to one embodiment of the present invention.

FIG. 3 is a perspective view of an example gauge module according to one embodiment of the present invention as illustrated in FIG. 1.

FIG. 4 is a perspective illustration of the modular gauging element assembly of FIG. 1 in an installed configuration.

DETAILED DESCRIPTION

Referring now in greater detail to the drawings in which like numerals indicate like parts throughout the several views, FIGS. 1-3 illustrate a modular gauging element system 10 according to one example embodiment of the present invention. The modular gauging element assembly 10 generally is adapted for use in a tufting machine for use in mounting a series of gauging elements or parts 11 at desired spacings for the tufting machine. For example, the tufting machine can include a series of needles and loopers or hooks, shown at 12 and 13, respectively, mounted in modules or directly along one or more needle bars or hook bars, respectively, within a tufting zone 14 of the tufting machine T for forming a series of loops or tufts 16 of yarns 17 within a backing material 18 moving through the tufting zone. As further indicated in FIG. 1, as the needles 12 are reciprocated vertically into and out of the backing material, they carry a series of yarns 17 fed from a yarn feed system or mechanism 19, into the backing material. As the needles approach their full, downward stroke, the yarns 17 are engaged by loopers or hooks 13 below the backing material so as to be picked and pulled from the needles in order to form the tufts 16 within the backing material 18.

As indicated in FIGS. 1, 2, and 4, the modular gauging element assembly 10 of the present invention typically includes an elongated gauge bar 21 that is mounted to a reciprocating drive mechanism 22 so as to move the gauge bar 21, and thus the gauging elements 11 mounted thereto in a reciprocating motion toward and away from the needles 12 as the needles penetrate the backing material 18, as indicated by arrows 23 and 23′ (FIG. 1). As further indicated in FIGS. 2 and 4, the gauge bars 21 can comprise a hook bar, needle bar, or similarly elongated gauge bar typically including an upper surface 26, lower surface 27, rear side 28 and a front facing side 29.

A series of spaced openings 31 further are formed in the front facing surface 29 of each gauge bar 21. While the openings 31 are shown in one example embodiment as substantially rectangularly shaped channels or recesses that extend vertically through the front facing surface of the gauge bar, between the upper and lower surfaces 26 and 27 thereof, other types or configurations of such openings, including substantially horizontally oriented slots, recesses, channels, one or more substantially circular holes, or other similar elements/openings also can be formed in the gauge bars. Additionally, an elongated shoulder or ledge 32 further typically will be formed along the lower edge or corner portion between the lower or bottom surface 27 and forwardly facing surface 29 of the gauge bar, extending longitudinally along the length of the gauge bar and forming a recessed area below the slots or openings 31 thereof. As indicated in FIGS. 2 and 4, the openings 31 formed in the gauge bar 21 thus act as receiving sites or areas for receiving a series of modules 35 holding the gauging elements or parts 11, in the example illustrated in the drawings being shown as a series of loopers or hooks 13, therein for mounting the gauging elements 11 to the gauge bar 21.

As indicated in FIGS. 2 and 3, each of the gauge modules 35 generally includes a module body 36 typically formed from a metal, such as aluminum or steel, or other similar rigid, durable material. The body of each gauge module further generally includes an upper surface 37, a lower or bottom portion 38, spaced parallel sides 39, a rear face or side 41, and a front face or side 42. As indicated in FIG. 3, the rear face 41 further includes an upper section 43 that extends or projects rearwardly from the body 36 of the gauge module 35, and a recessed lower section 44 below the upper section 43. One or more first guide members or locating elements/devices 46 (FIG. 3) also generally will be formed along the rearwardly facing surface 47 of the lower section 44 of the rear side 41. While such a guide member or locating element is illustrated in the drawings as possibly including a tab or similar projection, it will also be understood that other types of locating elements, such as one or more pins, projections, tabs, blocks, ribs, a detent, or other similar locating elements or devices can be mounted or formed along the rearwardly facing surface 47 of the side 41 of the gauge module body 36. These locating devices or guide elements 46 generally are adapted to engage and/or fit within the corresponding receiving openings 31 (FIG. 2) formed along the gauge bar 21, so as to assist in horizontally locating and mounting the gauge modules 35 to the gauge bar 21 in a desired horizontal alignment or position.

The rearwardly extending upper section 43 of the rear face or side 41 further typically engages or rests on the upper surface of the gauge bar, as indicated in FIG. 4, so as to provide an upper stop or limit to further help vertically position the gauge modules along the gauge bar. In addition, a second or lower locating element or member 48 generally can be formed along the lower portion 38 of the module body 36, projecting rearwardly from the rear face or side 41 as indicated in FIGS. 2, 3 and 4. The lower locating element 48 can be formed as a shoulder, ledge, or similar projection and can be formed as an integral part of the vertically extending locating or guide element 46, or as a separate component. In addition, other types of locating elements including pins, tabs, a tongue, or other similar device(s) also can be formed along the lower portion 38 of the gauge module body 36. This lower locating element 48 is adapted to engage the shoulder or ledge 32 formed in the front facing surface 29 of the gauge bar 21, along the lower surface or edge 27 thereof. As a result, the gauge modules are provided with a second vertical fixation point, generally indicated by 49 in FIG. 4, which helps to further vertically locate and substantially fix the gauge modules in a desired vertical position along their gauge bars. Such a construction further enables the gauge modules 35 to be more resistant to the upward pulling movements or motion acting thereon as a result of the yarns caught or engaged by the gauging elements 11 pulling upwardly on the gauging elements as the needles are reciprocated out of engagement with the banking material.

As additionally indicated in FIGS. 2 and 4, a fastener 51 generally is received through a fastener opening 52 formed through the body 36 of each gauge module 35. Each fastener 51 generally can include a screw, rivet, bolt or similar fastener, and generally will be extended through each fastener opening 52 and into engagement with a corresponding fastener opening 53 (FIG. 2) of the gauge bar 21. The fasteners help secure the gauge modules 35 in place along the gauge bar 21.

As further indicated in FIGS. 2-4, the front face or side 42 of each gauge module body 36 generally includes an upper portion 60, and an inwardly sloping or tapered lower section 61 extending downwardly therefrom. A series of spaced openings or slots 62 generally are formed in the front surface 63 of the upper portion 60 of each gauge module, which slots generally extend rearwardly through the body 36 of each gauge module 35. As further indicated in FIG. 3, the slots can extend to the rear face or side 41 of the module body, such as for use in level cut loop looper or hook assemblies, so as to provide a passage for movement of extensible clips through the module body, and further generally will extend at least partially along the upper surface 37 of the module body. The slots define a series of openings in which the gauging elements 11 are received within the body 36 of each gauge module 35 as illustrated in FIGS. 2-4.

The gauging elements or gauge parts 11 are shown in the drawings, for purposes of illustration, as including cut pile hooks or loopers 13, or alternatively, as level cut loop loopers or hooks 13′ as indicated in FIG. 3. It will be understood, however, that various types of gauging elements can also be utilized with the modular gauging assembly of the present invention, including loop pile loopers, cut pile hooks, needles, reeds, level cut loop loopers or hooks, or other gauge parts. As indicated in FIG. 2, such gauging elements can be removably secured with the body of each gauge module, such as by use of one or more fasteners 64 inserted into the front face of each gauge module in desired positions for securing the gauging elements in place within their gauge module. Alternatively, such gauging elements also can be cast in place within their gauge modules as a single, unitary structure, with the gauge modules typically being cast from the metal material such as aluminum, or other, similar material.

For installation of the gauge modules 35 of the modular gauging assembly 10 of the present invention, after the gauge bar has been installed within the tufting machine, each gauge module can be aligned with the desired receiving opening of the gauge bar and slid or pivoted upwardly from below the gauge bar and will be substantially automatically guided and located in their desired location or placement both vertically and horizontally along the gauge bar. Thereafter, the gauging modules can be fixedly mounted in place by the insertion of the fasteners 51 (FIGS. 2 and 4) therein, to complete the installation of the gauge modules along their gauge bar.

As a result of the construction of the present invention, the gauge modules can be quickly and easily located both horizontally and vertically so as to enable substantially greater uniformity of alignment of the gauging elements or gauge parts within the tufting machine. In addition, removal and installation of the gauge modules on a finished or operational tufting machine is further facilitated by the simple removal of the fastener 51 and thereafter the removal and replacement of the gauge modules since the gauge modules are substantially automatically located within their desired or proper alignment along the gauge bars, which alignment can be easily monitored or checked and corrected, without having to break down and remove the gauge bar or other elements of the tufting machine in order to replace or reinstall the gauge modules. In addition, the lower locating element helps provide a further vertical fixation point for the gauge modules to help align/locate the modules on the gauge bar as well as helping resist any upward pulling movement or motion acting thereon due to the loops of yarns that are caught on the gauging elements and are being pulled upwardly with the retraction or reciprocation of the needles out of the backing material so as to further help reduce pull-back or back robbing of the yarns and enhance uniformity of the tufts of yarns being formed in the backing material.

It will be further understood by those skilled in the art that while the present invention has been described above with reference to preferred embodiments, numerous variations, modifications, and additions can be made thereto without departing from the spirit and scope of the present invention as set forth in the following claims. 

1. A modular gauging element assembly for a tufting machine, comprising: a series of gauge modules each including a module body having a front face, a rear face, an upper portion, a lower portion, and a plurality of spaced openings formed in said upper portion and said front face of said module body; a gauge bar mounted within the tufting machine, adapted to receive said gauge modules in desired positions along the gauge bar and including a shoulder formed along a lower portion of said gauge bar; at least one guide member located along said rear surface of each module body and adapted to engage said gauge bar to horizontally align each gauge module along said gauge bar; a locating element extending transversely along said lower portion of each module body and adapted to engage said shoulder of said gauge bar to vertically align and support said gauge modules along said gauge bar; a fastener received through each of said gauge modules and engaging a corresponding fastener opening within said gauge bar when said guide member of said gauge module is received in its desired position along said gauge bar; and a plurality of gauge elements each received within one of said spaced openings of said module bodies of said gauge modules.
 2. The modular gauging element assembly of claim 1 and wherein said gauge elements comprise loop pile loopers.
 3. The modular gauging element assembly of claim 1 and wherein said gauge elements comprise cut pile hooks.
 4. The modular gauging element assembly of claim 1 and wherein said gauge elements comprise needles.
 5. The modular gauging element assembly of claim 1 and wherein each module body of said gauge modules is cast with said gauge elements mounted therein.
 6. The module gauging element assembly of claim 1 and wherein said gauge elements comprise level cut loop loopers.
 7. The module gauging element assembly of claim 1 and further comprising at least one fastener received within said module body of each gauge module for affixing said gauge elements within said spaced openings of each said module body.
 8. In a tufting machine for forming a series of tufts of yarns in a backing material, the improvement comprising: at least one gauge bar having a longitudinally extending ledge and a plurality of receiving sites located in spaced series along said gauge bar; and a plurality of gauge modules each comprising a front side, rear side, top and bottom portions, at least one first locating element along said rear side thereof and adapted to engage one of said receiving sides of said gauge bar for horizontally locating said gauge module along said gauge bar, and at least one second locating element adjacent said bottom portion of said gauge module and adapted to engage said ledge of said guide bar for vertically locating said gauge module along said gauge bar; and gauge parts received within said top portions of said gauge modules, projecting from said front sides thereof.
 9. The tufting machine of claim 8 and wherein said gauge parts comprise loop pile loopers.
 10. The tufting machine of claim 8 and wherein said gauge parts comprise cut pile hooks.
 11. The tufting machine of claim 8 and wherein said gauge parts comprise needles.
 12. The tufting machine of claim 8 and wherein said gauge parts comprise level cut loop loopers.
 13. The tufting machine of claim 8 and wherein each module body of said gauge modules is cast with said gauge parts mounted therein.
 14. The tufting machine of claim 8 and wherein said gauge modules further comprise a series of spaced slots each adapted to receive one of said gauge parts therein, and fasteners received along said front sides of said gauge modules for releasably mounting said gauge parts within said gauge modules. 